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Zonegreen Rail Depot and Workshop Safety Technology

Delivering intelligent technologies to offer protection from dangerous environments in a safe and efficient manner.

Zonegreen’s team of experts has developed an impressive range of intelligent technologies to offer safety-related products and innovative planning of train maintenance operations, and has forged an unrivalled reputation for quality, safety and reliability.

Depot personnel protection systems, interlocking solutions, as well as railway maintenance planning applications and out-of-gauge warning systems are installed worldwide and can be used in sectors as diverse as transport, petrochemicals and aerospace.

Depot personnel protection system

The Depot Personnel Protection System, commonly referred to as the Depot Protection System, is specialised and designed to ensure the safe and controlled movement of rail vehicles into and out of depots, so that maintenance operations can be conducted without endangering staff or the depot infrastructure.

Zonegreen’s SMART DPPS™ is highly advanced, state-of-the-art and incorporates intelligent, distributed communication technology, as well as electronic personnel datakeys to uniquely identify staff working in different safety zones.

The Zonegreen’s SMART DPPS™ allows the user to:

  • Login from any convenient point of access using a unique personnel datakey, replacing the need for padlocks
  • Easily identify personnel who are logged onto different roads
  • Interlock with other third-party equipment/systems to prevent unsafe movement
  • Protect working staff and other interlocked equipment from vehicle movement
  • Capture personnel logon/logout and movement history for future audit purposes

Additionally, where overview software is included, the status of Zonegreen’s SMART DPPS™ and personnel logged on will be visualised graphically from the depot manager’s office via a wall display.

Points converter for powering manual points

Designed to increase railway depot and workshop safety and efficiency, the Zonegreen Convertor allows the automation and remote operation of manual / hand points switches and rail road crossings.

Benefits of powering your manual points

  • Enhanced safety by reducing the potential for slips, trips and falls
  • Increased depot efficiency and speeding up of operations by eliminating many stops and starts
  • Expandable: routes can be pre-set, re-configured and upgraded at any time
  • Traceability includes an event logging system that allows the depot manager to keep a record of the points operation
  • Low cost
  • LUL approved

The Zonegreen convertor system comprises two parts:

  • Point Machine Conversion System: a point machine conversion device is attached to an existing manually-operated switch without compromising the integrity of the existing mechanism. It does not require any civil works or changes in the operating procedures to be installed. Each converter can be used as a stand alone or multiple units can be installed operating together with routing
  • Radio Remote Operator’s Controller: an intuitive handset that allows the operator to remotely control the points system. It can be either hand portable or cab mounted. A centralised control system is also available via windows PC interface that offers route planning and visualisation. The radio controller can also be used in a route selection mode, whereby one command can operate several points and crossings simultaneously

Train maintenance planner

The planning of train maintenance operations is still commonly conducted on a big whiteboard located in the operations control room, on which the train units that require servicing, maintenance tasks, arrival and departure times are listed. These are updated manually either in a tabular form or on top of a graphical layout representing a bird’s eye view of the depot.

Zonegreen’s depot manager, as a multi-user, web-based graphical task planning application, is a cost-effective replacement of the whiteboard. It consists of two main views: a graphical layout representing the depot on which users can position trains and create and assign maintenance tasks, and a tabular layout to plan trains’ scheduled arrivals and departures.

The train maintenance function of the depot manager allows staff to:

  • Plan train-unit maintenance activities
  • Easily visualise train locations in graphical layout
  • Accurately update and synchronise maintenance information
  • Share and disseminate maintenance information to different locations in a convenient way
  • Capture maintenance activities and generate reports, reducing the manual tasks of filling in maintenance forms and paperwork

Safety interlocking systems

The concept of interlocking has been applied to create increasingly sophisticated systems with the potential to prevent personal injury or costly damage. These systems can stop unauthorised train movements or actions by personnel not following stipulated safety procedures.

A typical installation is vastly superior to a permit to work system (which depends on personnel obeying written rules); physically prevents access to high-level working platforms while overhead line equipment remains live; isolates power to overhead crane while OLE is live; and ensures a safe system of work.

Out-of-gauge warning system

Zonegreen’s out-of-gauge warning system has been developed in response to rail industry demand for a ‘gold standard’ in obstacle detection systems. It is based around a series of non-contact laser rangefinder sensors and prevents a train from leaving the depot if its side skirt has not been fully closed.

If the sensor detects any kind of obstruction, for example an open side skirt, it will trigger an alert on the outbound visual warning board and illuminate a driver warning stop board on the depot exit road. The stop signs will remain illuminated until the warning is reset via the master keyswitch.

The out-of-gauge warning system is flexible and has a range of programmable options, such as a delayed response to help prevent the triggering of false alerts. It may also be expanded to cover the entire side area of the vehicle using a multiple sensor arrangement.

Depot safety-related equipment

Zonegreen offers a range of safety-related equipment for depots, including but not limited to:

  • Ground position signals
  • High level or pit warning beacons – static or flashing
  • Klaxons
  • Speed indication detectors
  • Stop and proceed boards
  • Electronic wheel-detect switches (treadle switch)
  • Portable warning systems

Maintenance and installation works at rail and tram facilities

Zonegreen is now able to undertake additional servicing maintenance and installation works at rail and tram maintenance facilities (IRSE installers) in addition to its normal servicing of depot personnel protection and interlocking systems. Zonegreen now offers the following:

  • Points / switches
  • Track circuit renewal (IRSE licensed)
  • Signal including axle counters
  • Cable testing (SMTH standards)
  • Barrier systems
  • AWS & TPWS systems

Make an enquiry

Press Release

Zonegreen Extends Reach Across Emerald Isle

Zonegreen is expanding its presence in the Republic of Ireland, after installing a new warning system at Dublin’s Fairview Depot.

White Papers

Things Are Steaming Rapidly Ahead… Are All Depots Keeping Up?

Some rail maintenance depots seem to look, and operate, as if they are still in the steam age. All very quaint, but how efficient are they, and even more important, how safe for depot staff?


Sir John Brown Building

Davy Industrial Park

Prince of Wales Road


S9 4EX

United Kingdom

+44 114 230 0822 +44 871 872 0349 Depot Protection Railway Points Converter Planning Electronic Whiteboard

Zonegreen Images

Products and Services


Related Projects

Press Release

1 April 2020

Zonegreen is expanding its presence in the Republic of Ireland, after installing a new warning system at Dublin’s Fairview Depot.

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18 March 2020

Zonegreen is equipping Norwich’s Crown Point depot with its latest personnel protection technology as part of a £40m upgrade.

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11 March 2020

UK-based rail safety specialist Zonegreen is equipping Norwich’s Crown Point depot with its latest personnel protection technology, as part of a £40m upgrade.

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21 February 2020

Yorkshire-based rail safety company Zonegreen has upgraded its technology at a second Siemens depot in the UK.

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15 January 2020

Zonegreen has upgraded its technology at a second Siemens UK depot as part of a major midlife overhaul programme.

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3 December 2019

Zonegreen has been chosen by Australia’s Downer Group to supply worker protection technology at a second train maintenance facility.

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28 October 2019

Zonegreen is to supply its flagship technology to Metro operator Nexus’ £8.4m training facility, which is being constructed in South Shields, UK.

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11 September 2019

Zonegreen is celebrating the achievements of its technical director, who has been driving up safety standards within the rail industry for the last two decades.

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5 August 2019

Zonegreen, the Sheffield-based rail safety specialist, is working with Siemens to renovate the personnel protection systems installed at its UK maintenance depots.

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24 June 2019

Zonegreen is assisting the workers who are helping to develop one of the Middle East’s most high-profile transport projects with a level of safety to match.

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15 April 2019

Zonegreen is providing advanced technology for the Crown Point rail depot in Norwich, UK, designed to prevent accidents and offer protection to staff.

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15 March 2019

Zonegreen is urging depot operators to review their earthing procedures to ensure personnel working with overhead lines are adequately protected.

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3 December 2018

Staff working on Qatar’s advanced driverless metro in Doha will be among the safest in the world with innovative depot protection technology from Zonegreen.

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31 October 2018

Zonegreen's flagship technology has been installed for staff working the overground fleet in London, UK, in order to avoid accidents when carrying out maintenance at height.

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26 September 2018

A new and advanced railway maintenance facility in Banbury, Oxfordshire, UK, is operating smoothly and safely with Zonegreen’s Depot Personnel Protection System™ (DPPS).

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28 August 2018

Zonegreen has finalised a five-year deal with Bombardier that will safeguard workers looking after London’s new Elizabeth line trains.

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21 August 2018

Zonegreen has installed its first main Depot Personnel Protection System (DPPS™) at a UK train building facility.

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30 July 2018

Zonegreen has recently installed its first flagship Depot Personnel Protection System (DPPS™) at Alstom's train manufacturing facility in the UK.

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22 November 2016

Zonegreen has completed the first international installation of its next generation Depot Personnel Protection System (DPPS™) at Wulkuraka in Ipswich, Queensland, Australia.

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29 September 2015

Rail depots being built for the government's flagship Intercity Express Programme (IEP) will benefit from cutting-edge safety systems, courtesy of Sheffield-based Zonegreen.

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29 July 2015

Sheffield-based Zonegreen is launching a new version of its flagship rail depot safety system, in response to increasing interest from clients across the globe.

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22 July 2015

Sheffield-based Zonegreen has received recognition for its technological expertise and high-quality performance from one of the world's largest rail industry companies.

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17 July 2015

Rail safety specialist, Zonegreen, is marking a milestone moment in its history, as the 1,000th order of its depot protection equipment prepares to leave the firm's Sheffield headquarters.

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16 July 2015

Zonegreen is expanding its product range to improve efficiency and working conditions for drivers and shunters operating freight and train vehicles.

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15 January 2014

The next generation of trains in New Zealand will not only be faster and more efficient, but also safer to maintain, thanks to Sheffield-based Zonegreen. Technology developed by the South Yorkshire depot safety specialist has been commissioned to protect workers at a new state of the art maintenance facility in Auckland.

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3 September 2013

Workers at a new £150 million train depot in Reading are among the safest in the UK, thanks to innovative technology supplied by Sheffield's Zonegreen. The rail safety specialist has installed its SMART Depot Personnel Protection System (DPPS) at the Berkshire facility to control the movement of trains and help safeguard staff.

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9 May 2013

Innovative software developed by Sheffield's Zonegreen is keeping operations at Italy's most advanced rail depot running smoothly and efficiently. Alstom has installed the South Yorkshire rail safety specialist's Operator Planning Suite (OPS) to oversee all of the daily functions in its maintenance centre near Nola.

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21 March 2013

Rail safety specialist, Sheffield-based Zonegreen, is transforming a Victorian maintenance facility into one of the most secure and efficient depots in the UK. London Midland's Tyseley depot, near Birmingham, is the latest British facility to implement Zonegreen's market leading SMART Depot Personnel Protection System (DPPS).

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5 March 2013

Safety is of critical importance to the rail industry as a whole, from senior management downwards. However, it can also be good for business. Sheffield-based rail safety expert Zonegreen says the demand for innovative safety solutions is helping drive the company's product expansion in the UK and abroad.

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1 February 2013

The product, which has been in development for two years, represents a leap forward in derailer assembly technology, and is thought to be completely unique in the market. It builds on Zonegreen's previous model, which is used widely on rail track across the UK.

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21 March 2012

Sheffield-based Zonegreen is turning the organisation upside down and taking the groundbreaking SMART DPPS™ (depot personnel protection system) product to Australia, in partnership with Australian firm Andrew Engineering.

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31 August 2011

A state-of-the-art Points Converter, designed to improve safety, efficiency and traceability, has been launched by Zonegreen in response to demand for a cost-effective automated solution. The convertor enables the automation and remote operation of any manual points, switches and rail ro

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5 July 2011

A decade after first working together, rail transport giant Alstom has invited UK rail safety company Zonegreen to provide the latest in depot protection systems at a number of traincare facilities, including Polmadie and Wembley. Alstom – manufacturers of the AGV, TGV and Eurostar seri

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9 June 2011

Zonegreen is delighted to present its brand new product, closing force monitor (CFM). The zonegreen CFM is a unique device in the railway industry designed to precisely measure and assess the closing force of train and tram doors. Specially engineered to ensure passenger safet

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8 June 2011

Zonegreen is now able to undertake additional servicing maintenance and installation at Rail and Tram maintenance facilities. Zonegreen is now able to undertake addtitional servicing, maintenance and installation works at rail and tram maintenance facilities (IRSE Installers) in additio

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14 April 2011

UK-based rail safety experts Zonegreen have completed the commissioning process for advanced safety equipment at major traincare depots in Wellington, New Zealand. With the co-operation of their Australian agent Andrew Engineering, the Sheffield-based company has supplied its SMART dep

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8 November 2010

Leading UK rail safety company Zonegreen has won a major contract to supply KiwiRail with state-of-the-art depot protection products as part of New Zealand's program of railways development. The Sheffield-based team of research engineers and scientists will supply its SMART™ Depot

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26 April 2010

The Dubai Metro Red Line will be fully open in a matter of months, and UK company Zonegreen is delighted to be playing a key safety role in the development of the world's most advanced automated metro network. The Sheffield-based team of research engineers and scientists was contracted

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8 April 2010

An innovative safety product, already nicknamed the 'skirt detector', has been launched this week by Zonegreen, and the first installation at Siemens' prestigious Heathrow Express depot has now been commissioned. The new Out of Gauge Warning System has been developed in response to rail

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15 March 2010

An innovative new derailer, designed for simpler installation and maintenance, and to withstand even the most extreme weather conditions, has been launched by Zonegreen. The product, which has been in development for two years, represents a leap forward in derailer assembly technology,

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2 February 2010

Leading UK-based rail safety company Zonegreen is urging SMART DPPS users to take advantage of Zonegreen's specialist 'Safety First' service contracts, in a drive to promote safety, reduce system downtime and maximise the lifespan of equipment. Christian Fletcher, technical director of

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24 November 2009

Leading UK-based rail safety company Zonegreen has become the first company in its sector to join forces with an Australian agent to launch its products into the fast developing Australian market. Until recently rail transport in Australia has been predominantly freight, but now &md

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11 November 2009

A team from Zonegreen will fly to Australia next week to take part in the largest annual rail event in the Asia Pacific region. The UK-based company – a world leader in the provision of standard rail safety solutions – will showcase its products to rail professionals from across the

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13 October 2009

A state-of-the-art traincare depot planning tool, which looks set to revolutionise operational efficiency and mark the end of the handwritten whiteboard, has been launched by Zonegreen. The UK-based company – a world leader in the provision of bespoke rail safety solutions – has

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Regional Offices


Sir John Brown Building

Davy Industrial Park

Prince of Wales Road


S9 4EX

United Kingdom

Gemma Houghton (Sales & Marketing Manager) +44 114 230 0822 +44 871 872 0349 Depot Protection Railway Points Converter Planning Electronic Whiteboard

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